A DIY flip-top cart is a great space-saver for a small workshop. This version was built 2 years ago using 2x4s instead of plywood. Let’s check in and see how it’s holding up.

You say you chose 2×4’s over plywood for ease of use. Without building another one to test, what is your gut feeling of the longevity and durability of your design…”

I thought Bill’s question was a good one. It’s been about 2 years since I built the cart, so it’s the perfect time to check in and see how the flip-top cart is holding up.

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What is a Flip-Top Cart?

Space is always at a premium in a small workshop and an easy way to save some space in a small shop is with a flip-top cart. A flip-top cart has table or top that flips or rotates from one position to another position. This feature allows tools, like a miter saw or bench-top table saw, to be mounted on one side, then the top can be flipped and the second side can be used as a workbench.

Why this DIY Flip-Top Cart is Different

Many flip-top carts are made with plywood. Those of us with small workshops know space is always at a premium and we also know maneuvering plywood in a small shop is nearly impossible.

My DIY fliptop workbench cart is made almost entirely with 2×4’s. The 2x4s were joined with pocket holes and wood glue. I opted to build my flip-top cart with 2x4s because it’s sooo much easier for me to maneuver 2x4s in my small workshop than it is to maneuver sheet goods.

However, I did use a little plywood for this project. My DIY fliptop workbench cart was made using two sheets of 2×4 plywood. These small sheets are waaaay more manageable in a small workshop. You could have your big box home improvement store cut down a sheet of 4×8 plywood for you, but then you would need a place to store the cutoffs.

How the DIY Flip-Top Cart is Holding Up 2 Years Later

So here’s the big question and the entire reason you’re reading this… How did it hold up? The short answer is the DIY fliptop workbench cart was a success! A big success! Even with all of that flip-top flipping the butt joints made with pocket holes and wood glue are still rock solid. The joints have not loosened at all and show no signs of wear or cracks. As a bonus I’ve managed to keep the workbench side of the flip-top cart free from glue spills with this silicone workbench mat.

Recently one of the barrel bolts broke, but I think that had more to do with a manufacturer defect rather than anything to with the flip-top cart itself. You can see that the surface of this barrel bolt started to oxidize while the others still look shiny and new.

I’m always trying to maximize storage in my small workshop, so after I built the DIY fliptop workbench cart I thought I could add some extra storage to that empty area in the bottom of the cart. I developed the free plans for this flip-top cart storage tray but later removed the tray.

Even with a dehumidifier, my workshop is pretty humid. The tray was mounted close to the floor and I goofed by not sealing or painting the plywood and the edges of the plywood began to get moldy. Needless to say, I removed the tray.

What Would I Do Differently?

There are a few things I would do differently if I were to build another flip-top cart. To give the piece a more finished look I think I might use my table saw to rip the rounded edges off the 2x4s. Why didn’t I do this on the original cart? Well, I know this will sound like a child stomping its feet, but I just don’t like ripping the rounded edges off 2x4s. I don’t know why, but the process really annoys me! Chances are you won’t see many projects from me using 2x4s with the rounded edges removed.

Second, I would paint the flip-top cart for the same reason I would rip the round edges off the 2x4s. Painting gives the piece a finished look. I painted the base for the Ultimate Workbench and I LOVE the way it looks. The base looks more like a store-bought piece rather than a DIY project.

Conclusion

A flip-top cart is a great space-saver for DIYers with a small workshop. Many flip-top carts are made with plywood, but what makes this version different is that it’s made with 2x4s. It was built about 2 years ago and is still rock solid.

Thank you for stopping by. If you found this information helpful, would you please pin it to Pinterest? Other DIYers would appreciate it and I would too! Thank you – Scott

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